Bicycle light generator

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In an attempt to incorporate a power storing functionality, we will also be studying a hand-crank generator powered flashlight.  Using the same principles as a generator powered bicycle lights, these flashlights also have a rechargeable battery pack that is able to store power; thus, allowing the user to operate a light without having to input energy at the same moment.
In an attempt to incorporate a power storing functionality, we will also be studying a hand-crank generator powered flashlight.  Using the same principles as a generator powered bicycle lights, these flashlights also have a rechargeable battery pack that is able to store power; thus, allowing the user to operate a light without having to input energy at the same moment.
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==Hand-Crank Generator Flashlight Components:==
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{| class="wikitable" border="1"
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|-
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! Part # !! Part name !! QTY !! Function !! Materials !! Dimensions !! Manufacturing Process !! Picture
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|-
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| 001 || Case || 2 ||
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* Protect working innerds from user and also provides a way for the user to hold
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* Aesthetics
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* Houses the on/off switch
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* Houses crank for powering the motor
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|| Plastic || 8" x 2" x 2" || Molding || [[Image:24441_Flashlight_Part_001a.jpg|25px]] [[Image:24441_Flashlight_Part_001b.jpg|25px]] [[Image:24441_Flashlight_Part_001c.jpg|25px]] [[Image:24441_Flashlight_Part_001d.jpg|25px]]
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|-
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| 002 || Case Screws || 4 ||
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* Securely fastens two sides of the case
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|| Metal || .3" x .2" x .2" ||  ||
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|-
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| 003 || Grips || 2 ||
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* Provide ergonomic support to the user
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* Hides case screws from being accessed
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|| Plastic || 12" x 5" x 3" || Injection Molding ||[[Image:24441_Flashlight_Part_003.jpg|100px]]
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|-
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|004 || On/Off Button || 1 ||
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* Guides paper
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* Protects user
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|| Rubber || .5" dia. || Stamped ||[[24441_Flashlight_Part_001a.jpg|100px]]
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|-
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|005 || Crank Handle || 1 ||
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* Creates moment arm allowing an easier motion to power motor
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|| Plastic || 3" x .5" x .25" || Molding || [[24441_Flashlight_Part_005.jpg|100px]]
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|-
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|006 || Crank Pivot || 1 ||
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* Allows the crank arm to be rotated circularly
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|| Plastic || 2" dia. || Molding ||[[Image:24441_Flashlight_Part_005.jpg|100px]]
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|-
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|007 || Crank Washer || 1 ||
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* Attaches crank assembly to case at a fix point while still allowing rotational motion
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|| Plastic || .75" dia. || Stamped ||[[Image:24441_Flashlight_Part_007.jpg|100px]]
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|-
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|008 || Crank Pin  || 1 ||
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* Keeps crank pivot attached to crank handle
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|| metal || .5" x .1" dia. || ||
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|-
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|009 || Crank Knob  || 1 ||
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* Provid user with a place to hold crank
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* Serves as a pin to keep crank housed inside case when not in use
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|| Plastic || .25" x .25" || Molding ||[[Image:24441_Flashlight_Part_005.jpg|100px]]
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|-
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|010 || Lens Cover  || 1 ||
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* Protects Led Housing
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|| Plastic || 3" dia. || Stamped ||[[Image:24441_Flashlight_Part_010.jpg|100px]]
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|-
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|011 || Output Spur Gear  || 1 ||
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* Drive shaft
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|| Plastic || 1" x 1" || Injection Molding ||[[Image:output_spur_gear_(7).jpg|100px]]
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|-
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|012 || Light Bulb Reflector  || 1 ||
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* Increases intensity of light
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|| Plastic+Aluminum || .5" x .5" x 1" || Injection Molding and Sheet Foil||[[Image:light_bulb_(7).jpg|100px]]
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|-
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|013 || Delay Trigger Housing || 1 ||
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* Houses the shredding cutoff time-delay
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|| Plastic || 3" x 1" x 1" || Injection Molding ||[[Image:safety_housing_(7).jpg|100px]]
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|-
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|014 || Cutoff Switch Time-Delay Trigger  || 1 ||
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* Triggers cutoff switch time-delay
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|| Plastic || 1" x 1" x .5" || Injection Molding ||[[Image:cutoff_switch_time-delay_trigger_(7).jpg|100px]]
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|-
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|015 || Spring for Child Safety Switch  || 1 ||
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* Hold the safety switch in position
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|| Spring Steel || 1/8" x .5" || Winding ||[[Image:spring_(7).jpg|100px]]
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|-
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|016 || Bow-Tie Washer  || 1 ||
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* Attaches auotmatic safety switch to the base cover
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|| Plastic || 1" x 1" x 1/8" || Injection Molding ||[[Image:bowtie_(7).jpg|100px]]
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|-
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|017 || Main Shaft Base Plate  || 1 ||
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* Hold axes aligned
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|| Plastic || 3" x 3" x 1/4" || Injection Molding ||[[Image:main_shaft_base_plate_(7).jpg|100px]]
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|-
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|018 || Cover Plate for Shaft Alignment  || 1 ||
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* Hold axes aligned
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|| Plastic || 2" x 2" x 1/4" || Injection Molding ||[[Image:Plastic_top_cover_(7).jpg|100px]]
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|-
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|019 || Gear Train Housing Base Plate  || 1 ||
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* Holds gears
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* Holds axes aligned
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|| Metal || 4" x 2" x 1/4" || Stamped ||[[Image:gear_base_plate_(7).jpg|100px]]
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|-
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|020 || Gear Train Housing Top Plate || 1 ||
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* Holds gears
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* Holds axes aligned
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|| Metal || 3" x 1" x 1/4" || Stamped ||[[Image:gear_top_plate_(7).jpg|100px]]
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|-
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|021 || Attachment Aligner for Motor Base Plate || 1 ||
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* Holds motor to gear train housing top plate
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|| Plastic || 1" x 1" x 1/4" || Injection Molding ||[[Image:motor_top_plastic_cover_(7).jpg|100px]]
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|-
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|022 || Screws  || 31 ||
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* Fastening
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|| Steel || #10-20 || Machined||[[Image:basket_(7).jpg|100px]] In the background
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|-
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|023 || Helical Blade  || 104 ||
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* Cut paper in diamond shape
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* Feeds paper
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|| Steel || .5" x 1\32" || Stamped ||[[Image:Helical_blade_cutters_(7).jpg|100px]]
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|-
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|024 || Flat Blade  || 8 ||
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* Feeds paper
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|| Steel || .5" x 1\32" || Stamped ||[[Image:flat_blade_cutters_(7).jpg|100px]]
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|-
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|025 || Paper Aligners  || 54 ||
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* Ensures proper feeding of paper
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|| Plastic || 1/2" x 1/4" x 1" || Injection Molding ||[[Image:white_aligner_(7).jpg|100px]]
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|-
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|026 || "Paper Aligner" Aligning Rod  || 2 ||
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* Aligns aligners
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|| Metal || 1\4" x 8" || Extrusion ||[[Image:cutting_assembly2_(7).jpg|100px]] Gold rod
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|-
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|027 || Long Main Shaft  || 1 ||
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* Driven by gear train
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* Turns blades
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* Aligns blades
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|| Steel || 10" x 1/4" || Machined||[[Image:cutting_assembly2_(7).jpg|100px]] Center rod
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|-
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|028 || Short Main Shaft || 1 ||
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* Driven by gear train
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* Turns blades
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* Aligns blades
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|| Steel || 9" x 1/4" || Machined||[[Image:cutting_assembly_(7).jpg|100px]] Center rod
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|-
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|029 || Basket || 1 ||
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* Collect shredded waste
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* Houses tab
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* Shredder assembly rests on top of basket
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* Keeps shredder assembly aligned
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|| Steel || 12" x 12" x 5" || Stamp ||[[Image:basket_(7).jpg|100px]]
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|-
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|030 || Tab  || 1 ||
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* Press safety switch
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|| Steel || 1/2" x 1/2" x 1/2" || Stamped ||[[Image:basket_(7).jpg|100px]] On the basket
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|-}

Revision as of 00:11, 1 February 2007

About

Bicycle light generators are used to power battery-less safety lights mounted on bicycles. Safety lights are important to bicycle enthusiasts alike as they provide the necessary lighting to traverse a road as well as inform auto drivers of the bikers presence at night. The generator converts the energy put into the bicycle in the form of a pedaling motion into an electric current through the friction developed by the generator’s contact with the wheel of the bicycle.


The purpose of the bicycle light generator project is to dissect and understand the design processes behind this product. Our goal is to study this product thoroughly in order to engineer a modification that will result in an improvement in its functionality.


In our preliminary observation, we have noticed that current generator powered bicycle light sets do not have a means of storing power. As a result, these generator powered bicycle lights do not operate when the bicyclist is not pedaling and could be hazardous when the stopped at a traffic light.


In an attempt to incorporate a power storing functionality, we will also be studying a hand-crank generator powered flashlight. Using the same principles as a generator powered bicycle lights, these flashlights also have a rechargeable battery pack that is able to store power; thus, allowing the user to operate a light without having to input energy at the same moment.


Hand-Crank Generator Flashlight Components:

Part # Part name QTY Function Materials Dimensions Manufacturing Process Picture
001 Case 2
  • Protect working innerds from user and also provides a way for the user to hold
  • Aesthetics
  • Houses the on/off switch
  • Houses crank for powering the motor
Plastic 8" x 2" x 2" Molding
002 Case Screws 4
  • Securely fastens two sides of the case
Metal .3" x .2" x .2"
003 Grips 2
  • Provide ergonomic support to the user
  • Hides case screws from being accessed
Plastic 12" x 5" x 3" Injection Molding
004 On/Off Button 1
  • Guides paper
  • Protects user
Rubber .5" dia. Stamped 100px
005 Crank Handle 1
  • Creates moment arm allowing an easier motion to power motor
Plastic 3" x .5" x .25" Molding 100px
006 Crank Pivot 1
  • Allows the crank arm to be rotated circularly
Plastic 2" dia. Molding
007 Crank Washer 1
  • Attaches crank assembly to case at a fix point while still allowing rotational motion
Plastic .75" dia. Stamped
008 Crank Pin 1
  • Keeps crank pivot attached to crank handle
metal .5" x .1" dia.
009 Crank Knob 1
  • Provid user with a place to hold crank
  • Serves as a pin to keep crank housed inside case when not in use
Plastic .25" x .25" Molding
010 Lens Cover 1
  • Protects Led Housing
Plastic 3" dia. Stamped
011 Output Spur Gear 1
  • Drive shaft
Plastic 1" x 1" Injection Molding
012 Light Bulb Reflector 1
  • Increases intensity of light
Plastic+Aluminum .5" x .5" x 1" Injection Molding and Sheet Foil
013 Delay Trigger Housing 1
  • Houses the shredding cutoff time-delay
Plastic 3" x 1" x 1" Injection Molding
014 Cutoff Switch Time-Delay Trigger 1
  • Triggers cutoff switch time-delay
Plastic 1" x 1" x .5" Injection Molding
015 Spring for Child Safety Switch 1
  • Hold the safety switch in position
Spring Steel 1/8" x .5" Winding
016 Bow-Tie Washer 1
  • Attaches auotmatic safety switch to the base cover
Plastic 1" x 1" x 1/8" Injection Molding
017 Main Shaft Base Plate 1
  • Hold axes aligned
Plastic 3" x 3" x 1/4" Injection Molding
018 Cover Plate for Shaft Alignment 1
  • Hold axes aligned
Plastic 2" x 2" x 1/4" Injection Molding
019 Gear Train Housing Base Plate 1
  • Holds gears
  • Holds axes aligned
Metal 4" x 2" x 1/4" Stamped
020 Gear Train Housing Top Plate 1
  • Holds gears
  • Holds axes aligned
Metal 3" x 1" x 1/4" Stamped
021 Attachment Aligner for Motor Base Plate 1
  • Holds motor to gear train housing top plate
Plastic 1" x 1" x 1/4" Injection Molding
022 Screws 31
  • Fastening
Steel #10-20 Machined In the background
023 Helical Blade 104
  • Cut paper in diamond shape
  • Feeds paper
Steel .5" x 1\32" Stamped
024 Flat Blade 8
  • Feeds paper
Steel .5" x 1\32" Stamped
025 Paper Aligners 54
  • Ensures proper feeding of paper
Plastic 1/2" x 1/4" x 1" Injection Molding
026 "Paper Aligner" Aligning Rod 2
  • Aligns aligners
Metal 1\4" x 8" Extrusion Gold rod
027 Long Main Shaft 1
  • Driven by gear train
  • Turns blades
  • Aligns blades
Steel 10" x 1/4" Machined Center rod
028 Short Main Shaft 1
  • Driven by gear train
  • Turns blades
  • Aligns blades
Steel 9" x 1/4" Machined Center rod
029 Basket 1
  • Collect shredded waste
  • Houses tab
  • Shredder assembly rests on top of basket
  • Keeps shredder assembly aligned
Steel 12" x 12" x 5" Stamp
030 Tab 1
  • Press safety switch
Steel 1/2" x 1/2" x 1/2" Stamped On the basket
Retrieved from "https://wiki.ece.cmu.edu/ddl/index.php/Bicycle_light_generator"
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